Tecnar Accuraspray CS Manuel utilisateur

User manual

In-line

cold spray

sensor

This document contains information considered proprietary and confidential to Tecnar Automation Ltee

40101-00075-00 –Rev A

Revision date: 2022-11-17

Page 1 of 51

NOTICES

No part of this manual may be reproduced in any form or by any means (including electronic storage and retrieval

or translation into a foreign language) without prior agreement and written consent from Tecnar Automation Ltd.

MANUAL PART

40101-00075-00 Revision A

The material contained in this document is provided “as is” and is subject to change without notice in future

editions.

Revision: November 17th, 2022

This document contains information considered proprietary and confidential to Tecnar Automation Ltee

40101-00075-00 –Rev A

Revision date: 2022-11-17

Page 2 of 51

Table of Content

TABLE OF CONTENT................................................................................................................................................................2

LASER SAFETY ........................................................................................................................................................................5

GENERAL PRECAUTIONS ........................................................................................................................................................................ 5

AUTHORIZED USE..................................................................................................................................................................................5

CLASS 4LASER SAFETY ........................................................................................................................................................................ 5

DESCRIPTION OF CONTROLS AND SAFETY FUNCTIONS .............................................................................................................................7

SYSTEM DESCRIPTION ...........................................................................................................................................................8

INTRODUCTION......................................................................................................................................................................................8

OVERVIEW ............................................................................................................................................................................................ 8

COMPONENTS DESCRIPTION ................................................................................................................................................9

CONTROLLER ...................................................................................................................................................................................... 10

SENSOR HEAD..................................................................................................................................................................................... 12

CABLES,HOSES AND ANTENNAS ........................................................................................................................................................... 14

SOFTWARE OPERATION.......................................................................................................................................................15

USER INTERFACE OVERVIEW ................................................................................................................................................................ 15

ACCESSING THE USER INTERFACE ........................................................................................................................................................ 16

CONNECTING TO THE SOFTWARE .......................................................................................................................................................... 17

LOGGING IN......................................................................................................................................................................................... 17

NAVIGATION TABS................................................................................................................................................................................ 18

LIVE SCREEN....................................................................................................................................................................................... 19

SELECTING ACTIVE GAUGES ................................................................................................................................................................. 21

ADJUSTING THE TIME SPAN................................................................................................................................................................... 22

ADJUSTING THE Y-AXIS DISPLAY ........................................................................................................................................................... 22

PART TEMPERATURE SCREEN ............................................................................................................................................................... 22

PRODUCTION REPORTS........................................................................................................................................................................ 23

SETUP SCREEN (OPERATOR AND ADMINISTRATOR ONLY) ........................................................................................................................ 24

MIN/MAX ADJUSTMENTS ....................................................................................................................................................................... 25

OPENING/DELETING SETUPS ................................................................................................................................................................ 26

SAVING SETUPS .................................................................................................................................................................................. 27

IMPORTING AND EXPORTING SETUPS ..................................................................................................................................................... 27

SETUP PARAMETERS ........................................................................................................................................................................... 28

SYSTEM SETTINGS............................................................................................................................................................................... 30

CHANGING THE USER PASSWORD ......................................................................................................................................................... 30

ENABLING/DISABLING WI-FI................................................................................................................................................................. 30

CHANGING THE STATIC IP OF THE CONTROLLER ..................................................................................................................................... 30

DHCP IP............................................................................................................................................................................................ 31

CHANGING THE PLC IP........................................................................................................................................................................ 31

REPORT GENERATION MODE ............................................................................................................................................................... 32

CHANGING THE TIME ZONE ................................................................................................................................................................... 32

UPDATING YOUR SYSTEM ..................................................................................................................................................................... 33

.................................................................................................................................................................................................33

PROCESS STABILITY.............................................................................................................................................................34

PHILOSOPHY AND MEASUREMENT PRINCIPLE ......................................................................................................................................... 34

OVERVIEW OF THE STABILITY PANEL...................................................................................................................................................... 35

THE DISTRIBUTION CHART .................................................................................................................................................................... 35

This document contains information considered proprietary and confidential to Tecnar Automation Ltee

40101-00075-00 –Rev A

Revision date: 2022-11-17

Page 3 of 51

THE CALCULATION METHODS ................................................................................................................................................................ 37

ADJUSTING THRESHOLDS BASED ON PREVIOUS RUNS ............................................................................................................................. 37

ADJUSTING THRESHOLDS MANUALLY BASED ON MULTIPLE RUNS.............................................................................................................. 37

TECHNICAL SPECIFICATIONS ..............................................................................................................................................38

SENSOR HEAD..................................................................................................................................................................................... 38

CONTROLLER ...................................................................................................................................................................................... 38

INSTALLATION........................................................................................................................................................................39

INSTALLING THE SENSOR HEAD ............................................................................................................................................................. 39

INSTALLING THE HMI MODULE .............................................................................................................................................................. 42

INSTALLING THE CONTROLLER .............................................................................................................................................................. 42

ADJUSTING THE SPRAY GUN POSITION................................................................................................................................................... 43

SETTING UP THE ACCURASPRAY ON A NETWORK (OPTIONAL) .................................................................................................................. 44

CONNECTING THE I/OS (OPTIONAL) ....................................................................................................................................................... 44

USING THE INPUT TO GENERATE REPORTS............................................................................................................................................. 44

MAINTENANCE .......................................................................................................................................................................46

MAINTENANCE SCHEDULE .................................................................................................................................................................... 46

MAINTENANCE PROCEDURES................................................................................................................................................................ 47

RECOMMENDED SPARE PARTS.............................................................................................................................................................. 48

TROUBLESHOOTING .............................................................................................................................................................49

LED ERROR CODES ............................................................................................................................................................................. 49

ERROR REPORTING IN THE USER INTERFACE.......................................................................................................................................... 50

SERVICE &SUPPORT ........................................................................................................................................................................... 51

This document contains information considered proprietary and confidential to Tecnar Automation Ltee

40101-00075-00 –Rev A

Revision date: 2022-11-17

Page 4 of 51

TABLE OF FIGURES

FIGURE 1: SCHEMATICAL DESCRIPTION OF THE SYSTEM ................................................................................................9

FIGURE 2: CONTROLLER (SIDE AND ISOMETRIC) .............................................................................................................10

FIGURE 3: SENSOR HEAD (FRONT).....................................................................................................................................12

FIGURE 4: SENSOR HEAD (BACK)........................................................................................................................................12

FIGURE 5: ACCURASPRAY CS USER INTERFACE .............................................................................................................15

FIGURE 6: ACCURASPRAY 4.0 LIVE SCREEN.....................................................................................................................19

FIGURE 7: ACTIVE GAUGES .................................................................................................................................................21

FIGURE 8: PART TEMPERATURE SCREEN .........................................................................................................................22

FIGURE 9: STRIPCHART BUTTONS BAR .............................................................................................................................23

FIGURE 10: SAVING PRODUCTION FILE..............................................................................................................................23

FIGURE 11: PRODUCTION FILES SCREEN..........................................................................................................................23

FIGURE 12: SETUP SCREEN.................................................................................................................................................24

FIGURE 13: GAUGES PROCESS CONTROL ZONES ...........................................................................................................25

FIGURE 14: OPENING/DELETING SETUPS ..........................................................................................................................26

FIGURE 15: UNSAVED SETUP MESSAGE............................................................................................................................27

FIGURE 16: SAVING SETUPS................................................................................................................................................27

FIGURE 17: IMPORT/EXPORT SETUPS................................................................................................................................27

FIGURE 18: SYSTEM SETTINGS ...........................................................................................................................................30

FIGURE 19: SYSTEM SETTINGS FOR NETWORK OPTIONS. .............................................................................................31

FIGURE 20: IO CONTROL TAB. .............................................................................................................................................32

FIGURE 21: SOFTWARE UPDATE EXAMPLE .......................................................................................................................33

FIGURE 22: STABILITY FEATURE TAB……….....……………………………………………………………………………………34

FIGURE 23: NORMAL DISTRIBUTION………………………………………………………………………………………………...35

FIGURE 24: UNPACKING THE PARTS………………………………………………………………………………………………..38

FIGURE 25: POSITION OF THE SENSOR HEAD ..................................................................................................................40

FIGURE 26: SENSOR HEAD MOUNTING PLATE DIMENSIONS. .........................................................................................40

FIGURE 27: MOUNTING THE SENSOR HEAD. .....................................................................................................................41

FIGURE 28: CABLE CONNECTIONS BETWEEN THE SENSOR HEAD AND THE CONTROLLER......................................42

FIGURE 29: SENSOR HEAD ALIGNMENT BUTTON. ............................................................................................................43

FIGURE 30: SENSOR HEAD WORKING DISTANCE. ............................................................................................................43

FIGURE 31: IO PORTS ON THE CONTROLLER....................................................................................................................44

This document contains information considered proprietary and confidential to Tecnar Automation Ltee

40101-00075-00 –Rev A

Revision date: 2022-11-17

Page 5 of 51

Laser Safety

The following precautions should be observed at all times while operating the Accuraspray CS. Tecnar Automation

Ltd. assumes no liability whatsoever for a user’s failure to comply with these precautions or the warnings

throughout this manual.

General Precautions

To protect your Accuraspray CS from damage, you must:

• Connect it to an unloaded, properly grounded power line (50–60 Hz., 100- 240VAC, 1.5 A).

• We also recommend using an additional power line filter to filter out any power surges or bursts.

• Use it at an ambient temperature between 4 and 45 °C.

• ALWAYS supply 30 LPM (2CFM) of cooling/cleaning air at 1.7–2.7 bar (25–40 psi) to the sensor head while the

unit is powered on.

• Use only original spare parts.

All Accuraspray CS users should read this user manual, take the web-based introduction and training sessions,

and contact Tecnar at servic[email protected] with any further questions. We also recommend that a copy of the

user manual should always be kept near the equipment.

Authorized Use

The Accuraspray CS is intended for use solely for cold spray process monitoring and control. Any other use is

regarded as unauthorized.

The Accuraspray CS has been designed and manufactured according to state-of-the-art technology and

recognized safety regulations. However, unauthorized use can result in danger to the operator or third parties’

body or even life and/or in damage to the product itself or other machinery.

Class 4 Laser Safety

The Accuraspray CS emits Class 4 laser radiation during operation.

Class 4 laser radiation hazards are defined as follows:

“Laser products for which intrabeam viewing and skin exposure is hazardous and for which the viewing of diffuse

reflections may be hazardous. These lasers also often represent a fire hazard.”

The Accuraspray CS contains two class 4 laser diodes with the emission overlapping at the point of measurement.

This document contains information considered proprietary and confidential to Tecnar Automation Ltee

40101-00075-00 –Rev A

Revision date: 2022-11-17

Page 6 of 51

Total laser emission:

Laser wavelength: 940 nm

Duration: Continuous wave

Nominal power: 20 W

Maximum power (fault condition): 40 W

Nominal laser density: 15.7 W/cm2

Beam divergence (each laser source): 3.3° Horizontal / 0.88° Vertical

Maximum permissible exposure: 31 W/m2

Nominal ocular hazard distance: 44 m (10 Second exposure time)

Radiation Pattern:

Both laser sources start near circular and become more elliptical the further away from the source they are.

Beam dimensions at window: 7.3mm horizontal by 6.8mm vertical.

Beam dimensions 200mm from the output: 18mm horizontal by 9mm vertical.

Eye protection:

Optical density: OD >= 4.62

Wavelength range: 900-1000nm

Radiation exposure (fault condition): 40 W

This document contains information considered proprietary and confidential to Tecnar Automation Ltee

40101-00075-00 –Rev A

Revision date: 2022-11-17

Page 7 of 51

Description of Controls and Safety Functions

1. Key Control:

The HMI Remote has a key switch which controls laser emission. When the key is removed laser emission is

disabled. The key must be inserted and turned to the ON position to be able to arm the lasers.

Note turning the key to the ON position does not automatically restart laser emissions, a manual start is required.

2. Remote Interlock Connector:

The controller has a two-channel remote interlock circuit. When the contacts are open-circuited, laser emission is

disabled. Both channels must be closed to be able to arm the lasers.

Note closing the contacts does not automatically restart laser emissions, a manual start is required.

It is recommended to use the interlock to control access to the laser environment. For example, an interlock on

the access door to the laser hazard area.

3. Sensor Head Beam Stop:

On the sensor head, a safety switch is provided. When the switch is turned to the vertical OFF position laser

emission is disabled. The switch must be turned to the vertical ON position to be able to arm the lasers.

Note turning the switch to the ON position does not automatically restart laser emissions, a manual start is required.

4. Manual Start and Stop Controls

The HMI Remote has two buttons to start and stop laser emission. If all the safety devices are clear to allow laser

emission, pressing the green button will start laser emission, and pressing the red button will stop laser emission.

The green button must be pressed to restart laser emission after any safety device has stopped emission or after

mains power to the controller has been lost.

5. Laser emission warning

The sensor head and the HMI Remote are both equipped with redundant indicator lights to indicate that the laser

is armed, and emission is possible. The lights remain on as long as the power to the laser is not completely

discharged, even if laser emission has stopped.

This document contains information considered proprietary and confidential to Tecnar Automation Ltee

40101-00075-00 –Rev A

Revision date: 2022-11-17

Page 8 of 51

System Description

Introduction

The present document gives a complete description and principle of operation of the Accuraspray CS sensor as

well as a description of its components.

Overview

The main purpose of the Accuraspray CS is to ensure consistent, high-quality coatings by monitoring the in-flight

particles and plume properties before each spray run. This ensures that the spray properties are within

predetermined acceptance ranges for ideal coating and performance.

To help detect potential issues such as partial clogging of the nozzle or in the powder injection system, and

instability of the powder feeder before the coating process, the Accuraspray CS monitors:

•Inflight particle velocity

•Relative powder feed rate

•Process Stability

•Standard deviation of all measurements

•Substrate temperature (optional)

The Accuraspray CS can also be used to:

•Develop and optimize spray parameters

•Transfer parameters from one booth to another (anywhere in the world)

•Transfer parameters from one spray gun to another

•Extend the useful lifespan of hardware

•Significantly reduce the number of test coupons

•Troubleshoot day-to-day issues

This document contains information considered proprietary and confidential to Tecnar Automation Ltee

40101-00075-00 –Rev A

Revision date: 2022-11-17

Page 9 of 51

Components Description

The Accuraspray CS system includes the following elements:

1. Controller

2. HMI unit

3. Sensor head

4. Air filter and hoses

5. Substrate pyrometer and its support bracket (optional)

6. Communication cable, laser power cable and safety switch cable

Each element is described in detail on the following pages.

FIGURE 1: SCHEMATICAL DESCRIPTION OF THE SYSTEM

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